Simulation of welded aircraft structures

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SummaryThe main objective of the project is to develop a technique for simulation of welding processes in order to allow appropriate evaluation of weldments local mechanical properties and further virtual testing of welded joints. The project will be focused on typical aircraft components manufactured from advanced high-strength aluminum alloys with the use of high energy density fusion welding processes, namely Laser Beam Welding and Electron Beam Welding.To achieve the aforementioned project objective, the following novel models will be developed and optimized with respect to the selected aircraft materials and manufacturing welding techniques:-Heat source model for prediction of the weld shape and dimensions-Metallurgical model for prediction of local material properties in the weld area and the Heat Affected Zone.When developed, both models will be calibrated with the use of experimental results obtained in welding and heat treatment experiments. Furthermore, both validated models will be implemented into the commercial FEM software for the 3-D simulation of welding technique. Incorporation of novel models into commercial software will result in high probability evaluation of temperature and stress distribution throughout entire welded joint, as well as in reliable estimation of weldments local properties for the selected materials and welding processes. In addition, the results of numerical simulation will be used as input data for numerical estimation (virtual testing) of welded joint strength under static loading.The results of virtual testing will be validated experimentally by comparison of the estimated strength of virtually welded specimens with real mechanical test data of welded joints. The proposed methodology of welding simulation technique, which combines numerical simulation with experimental model calibration, may be successfully applied for various parent materials, welded joint designs and welding conditions. It may also reduce significantly a number of welding trials and experiments during technology development phase. The results of welding simulation will be beneficial for either optimization of welding technologies or for improvement of welded components design in integral aircraft structures.